Wire dispensing system

ABSTRACT

A wire dispensing system for dispensing wire from a wire coil in a drum to a welding site. The system includes a wire feeder mounted on the top of the drum above the wire coil.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 11/965,813, filed Dec. 28, 2007 which is hereby incorporated by reference and which claims the benefit of U.S. Provisional Application No. 60/883,258, filed Jan. 3, 2007 which is hereby incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to a wire dispensing system for use with welding wire. In particular, the present invention relates to a wire dispensing system which enables continuous dispensing of wire from a wire coil to a welding site. The present invention also relates to a wire dispensing system which enables movement of the wire through a welding wire guide system where the wire coil is a long distance from the welding site.

BRIEF SUMMARY OF THE INVENTION

A wire dispensing system for continuous dispensing of wire from wire coils to a welding site. The system enables switching from a depleted wire coil to a new wire coil without having to stop the system or reload the system with the new wire. The system includes a frame and a wire feeder. The frame is used to position the wire coils in a side by side relationship and to mount the wire feeder above the wire coils. In one (1) embodiment, the wire coils are mounted in drums. The drums have a top with a slot which allows for dispensing of the wire from the drums and for automatic switching from one drum to the adjacent drum. The frame also includes a wire transfer arm spaced between the drums and the wire feeder. The wire transfer arm is pivotably mounted so as to be able to pivot from a position over one of the drums to a position over the adjacent drum. The wire transfer arm extends outward from the frame toward the drums and away from the wire feeder. The wire is attached to the wire transfer arm spaced apart from the center post of the frame and the wire feeder. The system can also be provided with guide conduits which extend from the drums to the inlet of the wire feeder and from the outlet of the wire feeder to the welding site. The guide conduits help to protect the wire and to correctly position the wire. The wire from the first coil is fed through the first guide conduit to the wire feeder through the wire feeder to the second guide conduit. The wire feeder is then activated to move the wire through the second guide conduit to the welding site. The wire feeder pulls the wire from the wire coil and pushes the wire to the welding site. The second end of the first wire coil is connected to the first end of the second wire coil. Thus, when the first wire coil is depleted, the wire is automatically dispersed from the second wire coil. As the dispensing of the wire moves from the first wire coil to the second wire coil, the wire pulls on the wire transfer arm and pivots the wire transfer arm from over the first wire coil to over the second wire coil to ensure that the wire continuously moves without interruption to the wire feeder and to the welding site. In a second embodiment, the wire feeder is mounted directly on the top of the drum. In this embodiment, the top has a cone shape with an opening in the apex of the cone.

The present invention relates to a weld wire dispensing system for continuously feeding wire from wire coils to a welding site, which comprises a frame for positioning the wire coils and a wire feeder mounted on the frame and spaced apart from the wire coils for pulling wire from the wire coils and pushing wire to the welding site.

Further, the present invention relates to a wire dispensing system for continuously moving wire to a welding site, which comprises a first wire coil having a first end and a second end, a second wire coil having a first end and a second end wherein the first end of the second wire coil is configured to be connected to the second end of the first wire coil, and a wire feeder spaced apart from the first and second wire coils and configured to receive wire from the first or second wire coil wherein in operation the wire feeder pulls the wire from the first or second wire coil and pushes the wire to the welding site.

Still further, the present invention relates to a wire dispensing system for continuously dispensing wire from wire coils to a welding site, which comprises a pair of drums, each drum configured to hold one wire coil, a frame for positioning the drums in a side-by-side arrangement having a center post positioned between the drums and extending upward beyond a top of the drums, a wire feeder mounted on the center post above the top of the drums, a first guide conduit extending between the top of the drums and the wire feeder, and a second guide conduit extending from the wire feeder toward the welding site, wherein the wire feeder pulls the wire through the first guide conduit and pushes the wire through the second guide conduit to the welding site.

Further still, the present invention relates to a system for feeding wire from a wire coil to a welding site which comprises a drum for holding the wire coil having a top with an opening and a wire feeder mounted on the top of the drum adjacent the opening for pulling wire from the wire coil out of the drum and pushing the wire to the welding site.

Still further, the present invention relates to a method for continuously providing welding wire to a welding site, which comprises the steps of providing at least two wire coils, providing a wire feeder, feeding the wire from one of the wire coils through the wire feeder to the welding site, activating the wire feeder so that the wire feeder pulls wire from one of the wire coils and pushes the wire to the welding site, connecting an end wire from one of the wire coils to a start wire of the other one of the wire coils, and switching from one of the wire coils to the other of the wire coils when one of the wire coils is depleted, wherein as the wire is dispensed from one of the wire coils and the end wire of the wire coil is reached, the wire feeder continues to pull on the wire so that the start wire of the other one of the wire coils is moved through the wire feeder so that the wire is provided from the other one of the wire coils and wire is continuously provided to the welding site.

The substance and advantages of the present invention will become increasingly apparent by reference to the following drawings and the description.

BRIEF DESCRIPTION OF THE DRAWING(S)

FIG. 1 is side view of the wire dispensing system 10 of the present invention showing the frame 12, the wire feeder 24 and the drum 20.

FIG. 2 is a front view of the wire dispensing system 10 showing the drums 18 and 20, the frame 12 and the wire feeder 24.

FIG. 2A is a schematic top view showing the slots 23 in the tops 19 of the drums 18 and 20.

FIG. 3 is a top view of the wire feeder 24 in the operating position with the wire 100 loaded through the wire feeder 24.

FIG. 4 is a top view of the wire feeder 24 without the drive roller 24 and the follower roller 38 showing the handle 42 in the open locked position with the handle 42 in the closed, unlocked position in phantom.

FIG. 5 is a top view of the wire feeder 24 without the drive roller 24 and the follower roller 38 with the bail 40 in the open, load position.

FIG. 6 is a front view of the drum 218 and top 219 of a second embodiment of the wire dispensing system 210.

FIG. 7 is a front, partial view of the top 219 of the drum 218 of the second embodiment showing the wire feeder 224 mounted on the inlet probe 227.

DETAILED DESCRIPTION OF THE INVENTION

All patents, patent applications, government publications, government regulations, and literature references cited in this specification are hereby incorporated herein by reference in their entirety. In case of conflict, the present description, including definitions, will control.

FIGS. 1 and 2 show the wire dispensing system 10 of the present invention. The wire dispensing system 10 enables continuous dispensing of welding wire 100 from wire coils 102 and 104 to a welding site (not shown). The wire dispensing system 10 includes a frame 12, a wire transfer arm 22, a wire feeder 24, and guide conduits 28 and 30. The system 10 also includes drums 18 and 20 which contain the wire coils 102 and 104. However, it is understood that the system 10 may be used with or without a container for the wire coils 102 and 104 and that any means for containing the wire coils 102 and 104 well known in the art may be used. The frame 12 allows for positioning a pair of wire coils 102 and 104 in first and second drums 18 and 20 in a side by side position. In one (1) embodiment, the frame 12 includes horizontal side arms 14 and a center arm 16 which form side-by-side stalls or openings which enable the wire coils 102 and 104 to be positioned adjacent to each other with the center arm 16 positioned between the wire coils 102 and 104. In another embodiment (not shown), the frame includes front and back side arms and front and back center arms which allows for the positioning of four (4) wire coils. The frame 12 includes a vertical center post 21 which extends upward beyond the top end of the drums 18 and 20. The vertical center post 21 is positioned between the drums 18 and 20. In one (1) embodiment, the frame 12 is constructed of aluminum. However, it is understood that the frame 12 can be constructed of any durable material.

Each of the drums 18 and 20 has a top or dome 19 positioned on the open, top end of each of the drums 18 and 20. The tops 19 are essentially identical. In one (1) embodiment, the tops 19 have a rounded shape. In one (1) embodiment, the top 19 is plastic. In one (1) embodiment, the outer edge of the top 19 has a shape similar to the shape of the drum 18 and 20, for example round, square or octagon. In one (1) embodiment, the top 19 completely covers the open top end of the drum 18 and 20. Each top 19 has a slot 23 having first and second ends 23A and 23B (FIG. 2A). The first end 23A of the slot 23 is adjacent the center of the top 19 and the drum 18 or 20. The second end 23B of the slot 23 is adjacent the outside edge or rim of the top 19 and the drum 18 or 20. In one (1) embodiment, the shape of the slot 23 from the center to the edge is arcuate similar to the path of the second end 22B of the wire transfer arm 22 as the transfer arm 22 moves from over the first drum 18 to over the second drum 20. In one (1) embodiment, the slot 23 extends from the center of the drum 18 in a direction toward the adjacent drum 20 and away from the center post 21. In one (1) embodiment, the slots 23 are a straight line from the center of the drum 18 and 20 to essentially the rim of the drums 18 and 20. The slots 23 of the tops 19 of each adjacent drum 18 or 20 are mirror images of each other. In one (1) embodiment, a bridge is provided extending between the second ends 23B of the slots 23 adjacent the edges of the drums 18 or 20.

A wire transfer arm 22 is pivotably mounted on the center post 21 spaced apart from and above the drums 18 and 20. The wire transfer arm 22 has opposed first and second ends 22A and 22B with the first end 22A pivotably mounted on the center post 21. In one (1) embodiment, the wire transfer arm 22 is essentially perpendicular to the center post 21 and extends outward from the center post 21 in a direction essentially toward the drums 18 and 20 and the wire coils 102 and 104. The wire transfer arm 22 is able to be pivoted between the side-by-side wire coils 102 and 104 and drums 18 and 20 (FIG. 2). The second end 22B of the wire transfer arm 22 opposite the center post 21 is positioned over one of the drums 18 and 20 essentially at the point where the wire 100 exits the drum 18 or 20. In one (1) embodiment, the second end 22B of the wire transfer arm 22 is directly over the center of the drum 18 or 20.

The wire feeder 24 is mounted on the center post 21 spaced above the wire transfer arm 22 and the drums 18 and 20. The wire feeder 24 is intended to be essentially permanently mounted on the frame 12. In one (1) embodiment, where the frame is used to position four (4) drums, a second wire feeder is mounted on the center post on a side opposite the first wire feeder 24. In this embodiment, each wire feeder services a pair of drums and a pair of wire coils. The wire feeder 24 has an inlet 24A through which the wire 100 enters the wire feeder 24 and an outlet 24B through which the wire 100 exits the wire feeder 24 (FIGS. 3 to 5). In one (1) embodiment the wire feeder 24 is similar to wire feeder described in U.S. Pat. No. 6,286,748 which is incorporated herein by reference in its entirety. However, it is understood that any device for moving wire 100 can be used. In one (1) embodiment, the wire feeder 24 includes a drive gear 34 having a drive roller 34 and a follower gear 36 having a follower roller 38. The diameter of the drive roller 34 and follower roller 38 is less than the diameter of the drive gear 34 and follower gear 36 respectively. The drive gear 34 is connected to the power source 26. The drive roller 34 is mounted on a spindle extending from the drive gear 34. In one (1) embodiment, the drive gear 34 and follower gear 36 are essentially identical. In one (1) embodiment, the driver roller and the follower roller 38 are essentially identical. The rollers 34 and 38 have grooves (not shown) around the perimeter of the roller to accommodate the wire 100 and to hold the wire 100 in the correct position. The follower gear 36 and follower roller 38 are mounted on a bail 40 which can be pivoted into an open, feed position away from the drive gear 34. A handle 42 holds the bail 40 in the closed, operating position. Pivoting the handle 42 unlocks the bail 40 and allows the bail 40 with the follower gear 36 and follower roller 38 to be pivoted to the open, load position (FIG. 4). In the open, load position, the wire 100 can be easily fed from the inlet 24A to the outlet 24B above the drive gear 34 adjacent the drive roller 34 or in a groove in the drive roller 34. After the wire 100 is fed through the wire feeder 24, the bail 40 is moved to the operating or closed position so that the teeth of the drive gear 34 engage the teeth of the follower gear 36. In one (1) embodiment, the handle 42 is adjustable so that the bail 40 can be adjusted with regard to the distance between the drive roller 34 and the follower roller 38 to allow for wires of various diameters. In use, when the power source 26 is activated, the drive gear 34 and drive roller 34 are rotated in a first direction which rotates the follower gear 36 and follower roller 38 in the opposite direction. The oppositely turning rollers 34 and 38 contact the wire 100 and move the wire 100 from the inlet 24A to the outlet 24B. In one (1) embodiment, the power source 26 for the wire feeder 24 is a pneumatic motor. In another embodiment, the power source 26 for the wire feeder 24 is an electric motor. In the embodiment where the power source 26 is pneumatic, after the wire 100 is fed through the feed device 24 and the bail 40 is moved to the closed, operating position, the air pressure on the regulator valve of the power source 26 is set at 0 psi. Next, the valve between the power source 26 and the wire feeder 24 is slowly opened. As the air pressure to the wire feeder 24 is increased, the wire feeder 24 starts to push the wire 100. The amount of air pressure to pull the wire 100 from the wire coil 102 or 104 and push the wire 100 to the welding site will vary depending on the diameter of the wire 100, the source or manufacturer of the wire coil 102 or 104, the type of conduit used for the guide conduits 28 and 30, the distance between the wire coils 102 and 104 and the wire feeder 24, the distance between the wire feeder 24 and the welding site and the amount of curves or the straightness of the guide conduits 28 and 30. In one (1) embodiment, the amount of air pressure is only enough as necessary to pull and push the wire 100. When set correctly, the wire feeder 24 stalls when the wire 100 is grasped or stopped and resumes movement of the wire 100 when the pressure on the wire 100 is released. In one (1) embodiment, the power source 26 for the wire feeder 24 provides eleven (11) inch pounds of torque at 60 psi. In another embodiment, the power source 26 provides thirty (30) inch pounds of torque at 60 psi. The size and amount of power provided by the power source 26 for the wire feeder 24 is dependent upon the size or diameter of the wire 100.

The guide conduits 28 and 30 of the wire guide system guide the wire 100 from the drums 18 and 20 to the inlet 24A of the wire feeder 24 and from the outlet 24B of the wire feeder 24 to the welding site (FIG. 1). In one (1) embodiment, the guide conduits 28 and 30 include a first guide conduit 28 and a second guide conduit 30. The first and second guide conduits 28 and 30 may be constructed of several individual pieces connected together. The first guide conduit 28 extends from the slot 23 in the top 19 of the drum 18 or 20 to the lower guide or inlet 24A of the wire feeder 24. In one (1) embodiment, the first guide conduit 28 is connected to the wire transfer arm 22 which enables the first guide conduit 28 to be moved from the slot 23 in the top 19 of the first drum 18 to the slot 23 in the top 19 of the second drum 20 when the first wire coil 102 is finished or depleted and the second wire coil 104 is started. In one (1) embodiment, the first guide conduit 28 is connected to the second end 22B of the wire transfer arm 22. The connection of the first guide conduit 28 to the second end 22B of the wire transfer arm 22 moves the first guide conduit 28 away from the center post 21 and allows the wire 100 to be dispensed from essentially a center of the drum 18 or 20. In one (1) embodiment, the first end of the first guide conduit 28 is positioned to extend slightly into the first end 23A of the slot 23 adjacent the center of the drum 18 or 20. Connecting the first guide conduit 28 to the second end 22B of the wire transfer arm 22 also offsets the first guide conduit 28 from the point where the first guide conduit 28 is connected to the wire feeder 24. Offsetting the first guide conduit 28 at the point where the wire 100 exits the top 19 from the wire feeder 24 and center post 21 provides a camming effect as the wire transfer arm 22 moves between the drums 18 and 20. The camming effect of the offset first guide conduit 28 helps to hold the wire transfer arm 22 in position over each of the drums 18 and 20. In one (1) embodiment, the first guide conduit 28 also includes a spring which allows the first guide conduit 28 to be flexible. The spring also helps to keep the wire transfer arm 22 in position over the drums 18 and 20. In one (1) embodiment, the first guide conduit 28 is insulated to prevent accidental electrification of the wire transfer arm 22. The second guide conduit 30 extends from the upper guide or outlet 24B of the wire feeder 24 to the feed rollers (not shown) adjacent the welding site. In one (1) embodiment, the second guide conduit 30 extends a distance between about 10 feet (3048 mm) and 100 feet (30480 mm) from the wire feeder 24 to the rollers adjacent the welding site. In one (1) embodiment, the second guide conduit 30 has bends and curves. It is understood that the guide conduits 28 and 30 act to guide and protect the wire 100 as it moves from the drums 18 and 20 to the welding site. However, it is understood that other means of guiding the wire 100 between the drums 18 and 20 and the welding site may be used.

In a second embodiment of the wire dispensing system 210, the wire feeder 224 is positioned directly on the top 219 of the drum 218 and services a single wire coil 102 (FIGS. 6 and 7). In this embodiment, the frame 12 is not used. In addition, in this embodiment, the system 210 must be deactivated before the wire coil 102 is replaced. In this embodiment, the top 219 of the drum 218 has a cone shape with a rounded apex. An opening 223 is provided in the apex of the top 219 through which the wire 100 exits the drum 218. The opening 223 in the top 219 has an inlet probe 227. The inlet 224A of the wire feeder 224 is mounted on the inlet probe 227 which secures the wire feeder 224 on the top 219 of the drum 218. An inlet support disk 229 can also be provided on the top 219 around the opening 223 to help support the wire feeder 224 on the top 219.

To use the wire dispensing system 10, the starting or first end 102A of the first wire coil 102 is manually fed into the first guide conduit 28 adjacent the slot 23 of the first drum 18. It is understood that the wire coils 102 or 104 are essentially identical and either wire coil 102 or 104 can be selected as the beginning or first wire coil 102. The wire 100 is moved through the first guide conduit 28 to the wire feeder 24. The wire 100 is loaded into the wire feeder 24 from the inlet 24A to the outlet 24B. The bail 40 of the wire feeder 24 is then moved to the closed, operating position. The wire feeder 24 is then activated to push the wire 100 through the second guide conduit 30 to the welding site. The finish or second end 102B of the first wire coil 102 is welded to the start or first end 104A of the second wire coil 104 so that the flow of wire 100 through the system 10 is continuous. In one (1) embodiment, the frame 12 includes a docking station (not shown) which allows for welding the ends 102B and 104A of the first and second wire coils 102 and 104 together. In one (1) embodiment, the frame 12 includes a bridge which provides support for the ends 102B and 104A to extend between the drums 18 and 20. When the first wire coil 102 is finished or depleted, the wire 100 from the second wire coil 104 is automatically fed into the wire dispensing system 10. In one (1) embodiment, as the first wire coil 102 is depleted and the wire 100 is dispensed from the second end 102B of the first wire coil 102 to the beginning or first end 104A of the second wire coil 104, the wire transfer arm 22 automatically moves from over the first drum 18 having the first wire coil 102 to over the second drum 20 having the second wire coil 104. The pull of the wire 100 in the direction of the second drum 20 overcomes the camming force tending to hold the wire transfer arm 22 in position over the first drum 18. As the wire transfer arm 22 moves, the wire 100 is moved in an arc or at an angle along the slots 23 in the tops 19 of the adjacent drums 18 and 20. As the wire 100 is drawn from the second wire coil 104, a new wire coil (not show) is moved into the first drum 18 and the starting end of the new wire coil is welded onto the finishing end or second end of the second wire coil 104. In an alternate embodiment, the drum 18 is removed and a new drum having the new wire coil is positioned in the frame 12 adjacent the drum 20 which is currently dispensing the wire 100.

After the wire 100 exits the drum 18 or 20, the wire 100 is moved to the inlet 24A of the wire feeder 24. Once the wire 100 is initially fed into the wire feeder 24, the wire feeder 24 pulls the wire 100 from the first wire coil 102 and pushes the wire 100 through the outlet 24B of the wire feeder 24 into the second guide conduit 30 toward the welding site. As the wire 100 is pulled from the first wire coil 102, the wire 100 moves along the curved inner surface of the top 19 to the slot 23 which reduces friction or drag on the wire 100 and in the system 10. As the wire 100 is pushed through the second guide conduit 30, the wire 100 is pushed toward the outside of any curve in the second guide conduit 30 which reduces friction or drag on the wire 100 and in the system 10. The amount of force on the wire 100 acting to push the wire 100 toward the welding site and between the rollers adjacent the welding site is selected so that there is very little drag coefficient on the rollers and no effort on the rollers. The amount of force pushing the wire 100 is selected so that there is little or no slippage of the wire 100 between the rollers. Eliminating slippage between the rollers enables constant flow of the wire 100 to the welding site. The use of the wire feeder 24 to pull the wire 100 from the wire coil 102 or 104 and push the wire 100 to the rollers enables the rollers to be used to move the wire 100 only a short distance from the rollers to the welding site. In one (1) embodiment, the wire 100 is moved at a rate of between about 50 to 1200 inches per minute. In one (1) embodiment, the amount of push force applied by the wire feeder 24 on the wire 100 is such that, if rollers adjacent the welding site stall or stop, the wire feeder 24 stalls, movement of the wire 100 stops and the wire 100 is pushed back toward the wire feeder 24 with a constant load. If the rollers stall or stop moving, the wire feeder 24 keeps a constant load on the wire 100 so that when the rollers begin to move, the wire 100 is moved at a constant and steady rate of flow to the welding site.

It is intended that the foregoing description be only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims. 

1. A system for feeding wire from a wire coil to a welding site which comprises: a) a drum for holding the wire coil having a top with an opening; and b) a wire feeder mounted on the top of the drum adjacent the opening for pulling wire from the wire coil out of the drum and pushing the wire to the welding site.
 2. The system of claim 1 wherein the top of the drum has a cone shape having a rounded apex, and wherein the opening is in the apex of the top.
 3. The system of claim 2 wherein the wire feeder has an inlet and an outlet and wherein the inlet of the wire feeder is positioned over the opening in the top.
 4. The system of claim 3 wherein a support disk is provided adjacent the opening for supporting the wire feeder.
 5. The system of claim 3 wherein the opening has an inlet probe and wherein the inlet of the wire feeder is secured on the inlet probe to position the wire feeder on the top of the drum and wherein the inlet probe guides the wire from the wire coil into the inlet of the wire feeder. 